Impact barrier for a storage unit

ABSTRACT

An impact barrier for a storage rack support structure includes an arcuate outer wall having opposed first and second ends, the first and second ends being spaced apart to form a gap therebetween. The impact barrier further includes a first deflection element, a second deflection element, and a third deflection element, wherein the third deflection element is positioned between the first and second deflection elements. The first deflection element extends from the first end to a first medial position on the outer wall between the first end and the third deflection element, and the second deflection element extends from the second end to a second medial position on the outer wall between the second end and the third deflection element. Upon impact, the first, second and third deflection elements deform to dissipate the energy generated by the impact.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority and is a continuation ofU.S. patent application Ser. No. 13/743,165 filed on Jan. 16, 2013, allof which is incorporated herein by reference in its entirety, and to themaximum extent allowable.

BACKGROUND

Support structures, such as for example, warehouse storage racks,upright supports, standing frames or columns are frequently subject todamage from contact by fork-lifts or other types of moving vehicles.

While protective barrier guards and/or guide rails, for example, may beuseful to protect the support member from contact by a moving vehicle,these safeguards are distant and removed from the support member itselfand do not offer protection when the support has received a directimpact load. It is known that a direct impact may compromise thestrength of the support resulting in an increased risk of collapse aswell as a risk of injury to nearby persons. In addition to repair and/orreplacement costs, such damage undoubtedly results in a generaldisruption in the business at hand (e.g., requiring the use of temporarystorage facilities, legal expenses connected with the defense of actionsresulting from an accident). Thus, there remains a need for protectingexposed surfaces of a storage rack, support or similar upright structureagainst impact damage.

SUMMARY

Described herein are improvements for protecting one or more exposedsurfaces of a structure such as, for example, a storage rack, support orsimilar upright structure.

According to one embodiment, an impact barrier for a storage racksupport structure includes an outer wall having opposed first and secondends, wherein the first and second ends are spaced apart to form a gap.The barrier further includes a first deflection element, a seconddeflection element, and a third deflection element, wherein the thirddeflection element is positioned between the first and second deflectionelements. The first deflection element extends from the first end to afirst medial position on the outer wall between the first end and thethird deflection element. The second deflection element extends from thesecond end to a second medial position on the outer wall between thesecond end and the third deflection element. The first and seconddeflection elements are non joining elements. In addition, the first andsecond deflection elements are not contiguous with the third deflectionelement. In response to an impact, at least one of the first, second orthird deflection elements deform to dissipate the energy generated fromthe impact.

According to another embodiment of the invention, the impact barrierincludes a first hinge disposed between the first medial position andthe third deflection element and a second hinge disposed between thesecond medial position and the third deflection element. Said first,second, and third deflection elements each have first and second ends.The first and second ends of each first, second and third deflectionelement are contiguous with an outer wall of the barrier. In one or moreembodiments, the first and second hinges facilitate movement of thefirst and second ends between a locked position to secure the protectorto the storage rack and an unlocked position. In one or moreembodiments, the first and second hinges enable expansion of the gap tofacilitate attachment and removal of the impact barrier from the supportstructure.

Generally, with the described embodiments, the outer wall is arcuate.The third deflection element may comprise a pair of connecting segmentsextending between the outer wall and a base portion, the base portionpositioned to abut a support structure. The first and second deflectionelements each include a planar segment positioned to abut and otherwisefrictionally contact the support structure. One of the deflectionelements is centrally positioned and generally has a larger surface areathan other deflection elements. At least one of the deflection elementsmay have a surface area that is at least about twice a surface area ofany of the other deflection elements. The length of the outer wall isoften about 1.5 times the cross-sectional diameter of the barrier. Atleast one of the deflection elements will abut a front surface of thesupport structure. In one or more of the described embodiments, at leasta portion of each deflection element may include a planar segment havinga surface that abuts the support structure. In some embodiments, a gripmay be positioned at or adjacent one or more of the first end of theouter wall, the second end of the outer wall and/or on at least some ofthe spaced apart deflection elements.

Still further as described herein is a method of making a device forpositioning on an upright, the method comprising: providing a two-partmold of the device; pouring a plastic material into the mold; allowingthe plastic material to set; and ejecting four to five inches of themold.

These and other embodiments and features and the advantages thereof,will become readily apparent from the following description, taken inconjunction with any exemplary representations, drawings and/or example.

BRIEF DESCRIPTION OF THE DRAWINGS

For more complete understanding of the features and advantages describedherein, reference is now made to a description along with accompanyingfigures, wherein

FIG. 1 is an illustration of an impact barrier for a storage racksupport structure;

FIG. 2 is top plan view of the impact barrier of FIG. 1;

FIG. 3 is an alternate perspective view of the impact barrier of FIG. 1;

and

FIG. 4 is top plan view of another impact barrier described herein.

DETAILED DESCRIPTION

In the embodiments illustrated in FIGS. 1 and 2, an impact barriermember 10 is employed to advantage and protect, for example, a warehousestorage rack, upright support, frame, column or other support structure,against damaging impact forces. For example, in the event a fork lift orother moving vehicle contacts a support structure 11 (FIG. 2), thebarrier member 10 deforms upon contact and otherwise absorbs the impactenergy that results from the impact force, thereby preventing orotherwise reducing the likelihood of damage to the support structure 11.

In the embodiment illustrated in FIGS. 1 to 4, barrier member 10includes an outer arcuate wall 12, deflection elements 24 a, 24 b, and24 c and living hinges 31 a and 31 b. As discussed in greater detailbelow, living hinges 31 a and 31 b facilitate ease of installation andremoval of barrier member 10 from the support structure 11. In thefigures, the outer wall 12 arcuately extends from a first end 12 a to asecond end 12 b. The first and second ends 12 a and 12 b are preferablyspaced apart a predetermined distance, which forms a gap 20, to enablethe barrier member 10 to fit around and frictionally secure to or aroundthe support structure 11. Preferably and in some embodiments, the outerwall 12 is generally c-shaped; however, it should be understood thatouter wall 12 may be otherwise shaped (i.e., rectangular, square, etc.).

Deflection elements 24 a and 24 b each reside and extend from the ends12 a and 12 b, respectively, to intermediate junctions 27, which arelocated at a medial point along arcuate wall 12. As such, deflectionelements 24 a and 24 b are, respectively, contiguous with a portion ofarcuate wall 12 and are not contiguous with each other or with any otherdeflection element. In FIGS. 1, 2, and 4, the deflection elements 24 aand 24 b each have a similar shape and surface area; however, it shouldbe understood that the deflection elements 24 a and 24 b may havedifferent surface areas and/or shapes. Preferably, each of thedeflection elements 24 a and 24 b contain at least a first segment 28having a planar region that is positioned to abut and otherwisefrictionally contact at least a portion of the vertical or horizontalsupport structure 11 around which the barrier member 10 is positioned,and the planar region is disposed beyond a plane A that extends throughintermediate junctions 27, and the planar region extends through a planeB formed by a dividing line 23 that divides the outer wall into a firsthalf and a second half, as best illustrated in FIGS. 1, 2 and 4.

The deflection element 24 c is formed of a base portion 25 and twoconnecting segments 27 a and 27 b. The connecting segments 27 a and 27 bextend from the outer arcuate wall 12 to respective ends 25 a and 25 bof base portion 25. In the figures, base portion 25 and first segments28 of deflection elements 24 a and 24 b define or otherwise provide abounded region 40 in the interior of the impact barrier 10 to receivethe support structure 11. Between ends 25 a and 25 b of base portion 25and a neighboring segment 28 are non-contiguous portions or gaps, suchas a gap between base portion 25 at end 25 a and neighboring and nonjoining segment 28 or a gap between base portion 25 at end 25 b andneighboring and non joining segment 28. As illustrated in FIGS. 1 and 2,the overall shape of the bounded region 40 generally conforms to theoverall shape of the support structure 11 on which the impact barrier 10is positioned. Also, in one or more embodiments, support structure 11 isgenerally bounded by and in contact with impact barrier 10 at a least aportion of each of deflection elements 24 a, 24 b and 24 c. In someembodiments, each of deflection elements 24 a, 24 b and 24 c include atleast one planar portion that assists in providing the bounded region40. In some embodiments, the planar portion may be flat and also arcuateor curved. As depicted in FIGS. 1 and 2, the arrangement of firstsegments 28 and base portion 25 forms a generally square shaped region;however, it should be understood that the base portion 25 and the firstsegments 28 can be arranged in any configuration, such as, for example,a rectangular configuration, an oval shaped configuration, a polygonal,a circular configuration or any other shape to conform to the crosssectional shape of the support structure 11, as represented in FIG. 4.

Referring specifically to FIGS. 1 and 2, the connecting segments 27 aand 27 b are generally curvilinear segments, such as, for example, “S”shaped, and have a first end portion 26 a, and a second end portion 26b. However, it should be understood that the connecting segments 27 aand 27 b may be otherwise shaped (straight or c-shaped, z-shaped,n-shaped, m-shaped, etc. and may be thicker, for example). Furthermore,as depicted in FIGS. 1 and 2, the drawings illustrate two connectingsegments 27 a and 27 b; however, it should be understood that a greateror fewer number of the connecting segments may be utilized. It should beunderstood, however, that other suitable arrangements may be made thatprovide energy absorption as a result of an impact load thereby reducingtransfer of energy to the vertical or horizontal support structure 11after impact to the impact barrier 10.

As illustrated in FIGS. 1 and 2, living hinges 31 a and 31 b aredisposed and extend respectively between the deflection element 24 a andconnecting segment 27 a and the deflection element 24 b and connectingsegment 27 c. The hinges 31 a and 31 b are of a selected thickness towithstand impact forces while also enabling sufficient flexibility topermit the gap 20 to expand, facilitating the installation and removalof the impact barrier 10 around the support structure 11. Flexibility ofthe living hinge is likely improved with the non contiguous nature ofthe deflection elements. When installing barrier 10 around the supportstructure 11, a force F can be applied to ends 12 a and 12 b to enablethe gap 20 to expand, such as to a less engaged or unlocked position,which will allow the support structure 11 to either be inserted withinthe bounded region 40 or removed therefrom. When the force F is removedfrom the ends 12 a and 12 b, living hinges 31 a and 31 b facilitate thereturn of the ends to their original or engaged or “locked” position toenable a frictional engagement of the barrier 10 to the supportstructure 11 (i.e., surfaces of first segments 28 and the base portion25 frictionally engage the support structure 11 at its outer surface).The impact barrier 10 is typically positioned such that the gap 20 isproximate to a surface opposed or away from a front or exposed surfaceof the support structure 11 or otherwise opposite the surface of thesupport structure 11 that typically receives the impact.

In the embodiment illustrated in FIGS. 1 and 2, a grip 22 is optionallypositioned to extend into or provide an additional boundary region forgap 20, said extension arising from each respective end 12 a and 12 b.Additionally or alternatively, a grip 22 may extend from any positionalong deflection elements 24 a and 24 b, which accommodates smallersupport structures 11 or alternatively shaped support structures notshown. A representative extension positioned along first segments 28 isdepicted in FIGS. 3 and 4. It should be understood that the grips 22 mayvary in size, positioning and overall length and remain sufficient toenable the barrier member 10 to be positioned on and otherwise securedaround the portion of the vertical or horizontal structure 11.

Generally, the outer wall 12 extends a length that is greater than itscross sectional diameter. For example, in some embodiments, the lengthof the outer wall 12 is 1.5 times a cross sectional diameter of theouter arcuate wall 12. In some embodiments, deflection elements 24 a, 24b, and 24 c may be at a different elevation than that of the outer wall12, thereby forming a recessed region on one or both opposinglongitudinal ends of barrier member 10, as representatively depicted inFIG. 3, in which a recessed region is formed at the lower longitudinalend of barrier member 10. The at least one recessed portion is oftenincluded to accommodate bolts or other mounting elements that are fittedwith or are on the vertical or horizontal structure 11.

In use, the impact barrier 10 serves as a bumper or protector,protecting the portion of the support structure 11 on which it ispositioned. It should be understood that one or a number of the impactbarriers 10 may be stacked or otherwise adjacently positioned along anyportion of the support structure 11, typically where damage is likely tooccur. In particular, the impact barrier(s) 10 may be positionedadjacent one another, at intervals, and/or at any of a number of impactpoints, as desired. When more than one impact barrier 10 is adjacentanother, the impact barriers 10 may be fitted, when desired, orotherwise secured together via a snap fit or other type of lockingarrangement or mechanism. It should be understood that a single impactbarrier 10 or plurality of impact barriers 10 do not require anchoringto the structure or anchoring to the ground or anchoring to each other.Furthermore, each impact barrier 10 does not require a tool forpositioning on the support structure 11. In addition, each impactbarrier 10 frictionally engages the support structure 11 and thus, doesnot require a belt, strap or closure once positioned on the portion ofthe vertical or horizontal structure.

Preferably, the impact barrier 10 is made of a material capable ofhardening, such as a hardenable plastic or hardenable polymer blend. Inone embodiment, the impact barrier 10 is formed of polypropylene. In thealternative, impact barrier 10 is formed of polyethylene, polycarbonate,polyvinylchloride, polystyrene or a mixture thereof, although othersuitable hardenable plastics may be used as desired. The impact barrier10 may optionally include a surface coating, weatherproofing,waterproofing, or an added scratch or stain or UV resistance covering orfinish. The exterior surface of the impact barrier 10 may also bedecorated with additional markings (e.g., advertising, strident marks)or finish. Furthermore, the exterior surface may include an embossmentor a debossment, as desired.

The impact barrier 10, when molded, may be formed using a highvisibility color in accordance with the Storage Equipment Manufacturer'sAssociation (SEMA) code of practice. The impact barrier 10 is preferablyformed using an injection molding process incorporating a two-part mold,one of which is a stationary part and another of which is a moveablepart. Because of the length of the impact barrier 10 described herein,which in one embodiment is at or about 9 inches or may be greater than 9inches (a length that is not easy to prepare for one of ordinary skill),one or more adjustments have been included with the method of making amember described herein in order to successfully arrive at a fullyformed and useful member. The process adjustments include increasing thestroke, increasing the number of ejector pins, and/or increasing theknockout bar.

The impact barrier 10, when molded, is shaped to absorb an impact force.In addition, the impact barrier 10 is shaped to dissipate an impactforce in more than one direction. Moreover, the impact barrier 10 may befurther adjusted and modified to add additional force dissipation and toalleviate deflection of impact forces to the structure itself. Forexample, the shape of deflection elements 24 a, 24 b, and/or 24 c may bemodified in shape to include more surface area.

In some embodiments, the length of the member described herein is aboutnine inches and the cross sectional diameter (taken with a measurementline passing through the center of the base member 25, as depicted inFIG. 2) is about six inches.

In one or more forms, when the outer shell 12 receives an impact, thedeflection element(s) 24 a, 24 b, 24 c nearest the compressive force arebent or otherwise deformed. The deflection element(s) 24 a, 24 b and/or24 c are provided to absorb and dissipate the compressive impact forcein more than one direction, so that the impact force will not damage thesupport member 11. Generally, the deflection element(s) 24 a, 24 band/or 24 c are also arranged to absorb and dissipate the compressiveimpact force in more than one direction and not directly to one anotherin view of their non-contiguous configuration.

To meet the requirements for protecting a rack leg against a forklift(which requires a protection of 15¼ inches), only two members describedherein would be required to be positioned side by side or in a stackingrelationship on the rack leg when each member is at or about 9 inches inlength.

Although representative processes and articles have been described indetail herein, those skilled in the art will recognize that varioussubstitutions and modifications may be made without departing from thescope and spirit of what is described and defined by the appendedclaims.

What is claimed is:
 1. An impact barrier for a support structure, theimpact barrier comprising: an outer wall forming an interior space; afirst deflection element extending into the interior space; a seconddeflection element extending into the interior space; a third deflectionelement positioned between the first deflection element and the seconddeflection element, the third deflection element extending into theinterior space, the third deflection element having a base segment; afirst living hinge and a second living hinge, the first living hingedisposed between the first deflection element and the third deflectionelement and the second living hinge disposed between the seconddeflection element and the third deflection element, wherein the firstdeflection element extends from a first position on the outer wall andjoins with the outer wall at a second position between the firstposition and the third deflection element, the second deflection elementextends from a third position on the outer wall and joins with the outerwall at a fourth position between the third position and the thirddeflection element, wherein at least a portion of the base segment ofthe third deflection element is parallel to a plane extending across thesecond position and the fourth position; wherein the first deflectionelement has two segments with ends intersecting at a first angle in theinterior space of the impact barrier and the second deflection elementhas two segments with ends intersecting at a second angle in theinterior space of the impact barrier; and wherein at least one of thefirst angle and the second angle is an obtuse angle.
 2. The impactbarrier of claim 1, wherein the outer wall is arcuate.
 3. The impactbarrier of claim 2, wherein a shape of the first deflection elementmirrors a shape of the second deflection element.